Welder World Blog

Archive for October, 2009

I want to research on what welding operations are needed when trying to weld large sections of steel together to form a hull of the ship.
what are the drawbacks and benefits of welding operations today for this kind of process?
what would be the best one for the job?
Thank you very much!

If you have a welding job and not sure what type of equipment you need or if you are working in an environment that needs flexibility in order to complete the job. There is the option of buying a portable welder, for your job’s task. They are a lightweight yet durable piece of machinery that can be used in or out of doors. They are even capable of being assembled on site.

The portable welder comes with many different optional features in general, but it is all up to the purchaser to determine what will and will not fit in both budget and work haul. Your portable welder should be a perfect fit for your type of welding needs. It should be dependable and safe for operation in your workspace.

Your portable welder should come with certain features to keep the operator and the material secure. There are some portable welders that are equipped with non overheating features, that work to keep the electrodes from over exposure to heat generated from the power supply engine. It is a great feature in a portable welder to have a monitor that will keep tabs on the current and voltage flow to make sure it is flowing in the way the job requires.

There are several types of portable welding machines, including those that come with a gasoline power generator. These are wonderful if you have no power or power isn’t available in your workspace. There are the portable welders that have a duality in AC (alternate current)/DC (direct current) power output. Even if you are in the need of constant power from the power source or supplier, there are some that are built to aid in keeping the electricity for welding perfect, for a better weld.

Some portable welders come equipped with a power backup not only in the form of a gas generator, but also there is the option of battery backup. The battery backup feature in a portable welder for some portable welders, have rechargeable batteries. This feature would more likely than not be more product specific, but should aid you in knowing that fact, while you are in search of one.

There are those portable welders that have a diesel and gas generator option for backup power. They are said to be compressed in size, lightweight, nearly noiseless, low fuel usage and are hand held. There are various ranges in voltage and current flows when it comes to portable welders and equipment.

As in any product you are purchasing, your goal overall is to find quality at a price you cant beat. When it comes to portable welders the sky is almost the limit in size, power backup, durability, and even in pricing.

I want to learn how to do some basic welding in my garage. Firstly , What will i need to get & where.
Secondly , Is there anywhere i can find information on how to do it?
Thanks for any help.

In order to help you choose IGBT or MOSFET Welders/Cutters, you will come to a conclusion more accurately after taking into consideration the pros and cons of both technologies, along with the purpose of their use, commercial/industrial/professional or enthusiasts. To make a decision you will need to understand what type of application you are going to use the welders for whether it is commercial welding or garage or small shop welding take your pick of equipment is the best alternative for those who wish to make an informed choice. Remember, the IGBT welders and cutters are bit a pricier so please take that into account as well.

Longevity MOSFET Welders/Plasma Cutters use MOSFET technology, which is most commonly used when the amplification or switching of electronic signals is the need of the hour. Longevity has designed welding equipment featuring MOFET technology to keep the cost low for hobbyist and enthusiasts. Longevity uses MOSFET technology in plasma cutters and welders that require less strenuous use or on less powerful, smaller amperage equipment. This technology, when applied in a welder/cutter can ensure optimum utilization of available electrical power so that too much power is not allowed to flow through the circuit gateway of the device. This technology of MOSFET Welders and plasma cutters is quite beneficial in ensuring that the gateways of coupling circuits do not burn out due to overexposure to high voltage current flow. This metal oxide semi conductor field effect transistor technology is a popular choice among users of welding equipment if they are looking for a compact yet highly efficient machine to perform exceptional welding jobs. This genre of welders has been gaining in popularity from the time the MOSFET technology was invented in 1959 by two extremely dedicated research scientists of Bell Labs who have been extremely devoted to electronic research. Since the invention, Longevity MOSFET plasma cutters and welders are enable the welding population to use smaller and more affordable welding/cutting equipment for their jobs.

IGBT Welders are those welding machines which employ the Insulated Gate bipolar Transistors in their internal electronic circuits. The IGBT is a power semi conductor device with three terminals well known for its high efficiency and fast switching. It is being fitted in many modern electronic appliances, including cars, stereo systems and even refrigerators, apart from IGBT. This technology is very effective where there is a high requirement of switching amplification. The IGBT Welders have technology that is designed to rapidly switch the device on and off, and this allows the machine to synthesize complex wave forms with both, pulse with modulations and low pass filters. The IGBT can compile the gate drive feature of MOSFET with the low saturation and high current capabilities of the bipolar transistors of former fame. The IGBT technology is used in controlling large amounts of power. These welders are quite popular with the users who require high pulse ratings in comparatively low prices. Longevity IGBT Welders and Cutters are built for more commercial and heavy duty applications. The use of this technology allows Longevity to provide welding equipment that is designed for professional and industrial job requirements.

Whichever of the two, MOSFET vs IGBT Welders/Plasma Cutters that you may choose, Longevity has a variety of models in both technologies and all can be viewed at www.longevity-inc.com. With easy transportability and a greater amount of superiority in the welder features, Longevity welders and plasma cutters are truly world class. If you are deciding which is better and still having a hard time concluding, please note that both IGBT or MOSFET technologies are covered by Longevity’s unmatched 5-YEAR parts and labor warranty. Without a doubt, an inexpensive means to achieve the perfect balance between technology and excellent output, the welder models that are available at Longevity truly offer a better durability to the clients.

Though the welding industry continues to vigorously defend itself against a growing tidal wave of welding rod litigation, it was dealt a serious blow in March 2006 when its repeated attempts to overturn a welding rod fumes case failed in the Illinois Supreme Court. The case is a landmark in welding rod litigation, in which former welders claim that exposure to fumes from welding rods caused manganism and even Parkinson’s disease.

The Original Case

Though several welding rod cases have produced multi-million dollar settlements, the original case in question is a landmark because it is the only welding rod verdict ever decided in favor of the plaintiff. The case, entitled Elam v. A.O. Smith, contended that the plaintiff, a 64-year-old Illinois welder who worked in the profession for 30 years, suffered neurological damage from long-term exposure to the toxic fumes that are a byproduct of welding rods. The case was previously tried before a hung jury (Illinois law demands a unanimous jury); Jack Elam was awarded $1 million in compensation during the retrial. The jury found that A.O. Smith failed to provide adequate safety warnings about the dangers of manganese in welding rod fumes.

The verdict was a watershed in more ways than one – it unleashed a wave of welding rod litigation once attorneys knew that it was possible for a verdict to be awarded in the plaintiff’s favor. The welding rod cases have become so numerous that a multi-district litigation is underway in Ohio; it numbers well over 3,000 plaintiffs.

Lost on Appeal

The defendants in the original case quickly appealed the case, contending that it did in fact adequately warn workers of the dangers of working with welding rod fumes. However, in December 2005, the 5th District Appellate Court of Illinois found that the company did not warn workers adequately, upholding the $1 million verdict. The court was taken before the Illinois Supreme Court on second appeal. Because of this, former welders filing litigation to receive compensation had elevated hopes of effectively winning future cases while the welding industry struggled to cope with the verdict.

Former Welders Cling to Hope; Continue to Litigate

Despite the fact that the $1 million verdict is the only one ever given to a welding rod litigant, former welders who are suffering from Parkinson’s, manganism and other occupational illnesses related to their welding work are retaining hope. Experienced welding rod lawyers believe that the Elam v. A.O. Smith will set a precedent that allows other litigants to collect damages for their occupational exposure to manganese. If you are suffering health problems due to your work as a welder, contact a doctor and then an experienced welding rod litigation attorney who can analyze your case and tell you whether you may be qualified to monetary damages.

We have been to wisconsn a long drive and we went threw a big thunderstorm in illinois with baseball sized hail which we didn’t get into and the lightning was so bright that you could see the road and the sides around the road like it was daylight and I have allways been told if you look at a welder it would burn your eyes and would lightning burn your eyes and mess with your vision?

We are all well aware that manufacturing and construction are never ending processes. As long as the world exists, there will be construction of some kind and manufacturing of some kind of products. In turn, as long as these two processes exist, there will be welding and fabrication. With more and more buildings erected each day and countless numbers of products manufactured, the demand for the welding & fabrication technology professionals is very high. At the moment, there is actually a shortage of skilled welding labors. Many huge firms are looking for talented welding and fabrication technology professionals today. These firms consider welding as an art and hence they are ready to pay good salaries for skilled Welding & Fabrication Technology professionals.

The quality of welding and fabrication work entirely depends on the skills of the professional. Though there is a huge demand for Welding & Fabrication Technology professionals, the big firms are looking for highly skilled labors. Welding & Fabrication Technology is a career that needs top-notch training to develop the skills you will need. The main advantage of getting trained in Welding & Fabrication Technology is that your career scopes are not confined to any specific industry. Welding & Fabrication Technology are required in the processes like bridge building, laying cross country pipelines, underwater welding and fabricating equipment in exotic materials such as titanium. For this reason, the career option in Welding & Fabrication Technology is unlimited.

Where do you get trained to develop unmatched skills in Welding & Fabrication Technology? With the huge increase in demand for Welding & Fabrication Technology professionals, many Associate Degree programs have spawned today. Today, it will be confusing to find the best Associate Degree program to learn the sophisticated technology of Welding & Fabrication Technology. However, there is something really special with the Welding & Fabrication Technology associate degree programs in the Pennsylvania Trade Schools. One of the main advantages of getting trained in the Pennsylvania Trade School is that the skills and degrees earned in Welding & Fabrication Technology through the Pennsylvania Trade School are valid in any Country. Therefore your career options will not be restricted within a state. You can seek career opportunities on Welding & Fabrication Technology in any state if you are trained in a Pennsylvania Trade School.

Getting trained in the best associate degrees programs for Welding & Fabrication Technology will make you prepared to develop new skills to meet different challenges. This will help you to boost your career growth.

Forge welding is said to be the oldest welding technique ever used by early blacksmiths, dating back to the Iron Age when ancient Egyptians and people from Eastern Mediterranean began to refine the craft of welding iron metals together.

Also known as “fire welding,” this method attempts to fasten together two or more metal components through a process of heating, hammering and striking. It is also the “simplest” solid-phase bonding method that utilizes heat and pressure to create the weld.

Being able to join a host of similar and dissimilar materials, forge welding is very versatile. Although this technology has been around for centuries, it was not until the first half of the second millennium A.D when forge welding was formalized upon the publication of Vannoccio Biringuccio’s book entitled “De la pirotechnia” in 1540. This book contains descriptions of early forge welding techniques. However, due to the advent of industrialization which gave birth to more sophisticated welding methods, this technique has been replaced.

There are two ways of doing forge welding. One way is through solid-state diffusion which is applied to bond two similar metal components. This results in a weld that contains only the welded metals with no bridging materials or fillers. This application requires tedious surface preparation because too much oxidation of the faying surfaces would lessen the joint strength significantly. Another method of forge welding is by the formation of a lower melting temperature eutectic. This is being done between dissimilar materials, allowing you to make weld that is stronger than individual metals.

One of the most popular applications of forge welding is the manufacturing of pattern-welded blades. In this process, steels are repetitively drawn out, folded back and welded upon itself. Another lesser known application is the production of shotgun barrels. In this method, metal wire is coiled onto a mandrel before forging it into a barrel.

For a forge welding job to be successful, 50-90% of the melting temperature is recommended. Take note that steel welds at a much lower temperature than iron. Utmost care must be taken to prevent overheating the metals.

where can i get a replacement gas tank for my lincoln welder prefferably a plastic 4 gallon?

Installing your mig welding wire is really quite simple. The first step is to make sure that you are using a very high quality mig welding wire. Why? You can have so many troubles with mig welding wire not feeding, burning back, excess spatter, birds nesting and so on.

Assuming there is no old spool of mig wire on the mig welder. The first think you have to do is physically open the welding machine or wire feed case up.

Then you will have to remove a cotter pin or a large plastic nut that is attached to the hub or axle the welding wire will slide onto. Now open up the box of mig wire, check that it is the correct size wire that you want to use and the correct type of wire. Also give it a quick glance and check for rust.

Lift up the spool and slide it onto the axle/hub. Replace the cotter pin or plastic nut.

Now go to the end of the mig welding gun and remove the nozzle / shroud. This will either pull off or screw off depending on the brand of welding torch. When it’s off, remove the contact tip by unscrewing it with pliers.

Set the nozzle and contact tip aside.

Go back to the mig wire, and in between the spool of mig wire and where the welding torch attaches to the front of the machine or remote wire feeder you will find the feed rollers or drive rollers.

There will be some kind of latch which can be flicked open. This action will raise the top feed roller and allow you to feed the wire onto the drive rolls.

Note that on the feed rollers there are usually two grooves. The wire needs to sit in one of these grooves. On the side of the feed rollers will be a punched marking showing what size wire to use in which groove.

Usually mig welding machines come with two different sized grooves. For example 0.9mm and 1.2mm which is 0.035” and 0.045”.

Make sure that the mig welding wire diameter fits the right sized grove in the feed roller. When running a precision welding wire you need to use the right feed roller groove for the correct diameter sized mig wire.

You can get away with using slightly different sized feed rollers when you run a cheapie low quality mig wire. Why is this? This is because the wire diameter tolerance will go up and down. So the wire will be getting thicker and thinner all the time which will compensate for the slightly wrong sized feed rollers.

I do not at all recommend this for anyone who is serious about making money in a production welding environment or welding and fabrication business. It will cause to much trouble.

Now you will have to carefully and I stress carefully find the end of the mig wire and hold onto it and don’t let go. If you do it will go whirl, whirl, whirl and you will have a big mess of mig wire all over the place.

With the end of the mig wire feed it into the driver rollers, you will have to go through a small feed tube. This helps guide the wire over the feed rollers.

Keep feeding the wire through past the driver rolls and into the start of the mig welding gun. Feed it through about a foot or so.

Lower and lock down the latch for the drive rollers, and adjust it right back to number one or the lightest setting possible. Then screw / adjust the tension down a bit.

Next if you are using gas, turn off the bottle to save your expensive welding gas lay you welding gun and cable out straight from the welder and pull the trigger. The wire will slowly fed through the liner and pop out at the tip holder. You can crank up the feed speed adjuster to get the wire through faster.

Now when the wire emerges put the contact tip or contact tube back on. Put the nozzle back on and trim the wire to about half an inch sticking out.

You are just about done now. Turn you gas back on. Now ideally you want the wire feed tension mechanism to be as light as possible so that it does not deform the shape of the welding wire. Deforming the shape of the welding wire will case premature wear on the feed rollers simply because of too much force. It will cause irregular wear on the contact tip and the welding wire will have tiny bits of material shaved and squeezed off it which will go down into the liner of the torch, and over time cause it to build up internal resistance which will cause more trouble welding down the track.

For more go here

http://www.learn-how-to-weld.com/mig-wire-installation.html

Cheers,

Peter Apalais